How to Remove Broken Bolts From a Cylinder Head
Bolts that break off in a cylinder head are extremely difficult to remove. About the only thing you can do is drill them out. Since there is a significant risk of damaging the threads on the engine head, this job is extremely difficult to do correctly. When it's all finished, you should have drilled through whatever is left of the bolt and removed all of the bolt pieces--but left the threads on the engine head in tact.
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Instructions
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1
Secure the drill bit into the drill and tighten the drill chuck counterclockwise.
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2
Fit a drill bit for the bolt. Choose a drill bit that is slightly smaller than the diameter of the bolt. You want to try to destroy the bolt without damaging the threads on the cylinder head.
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3
Create a starter groove in the bolt. Slowly drill a groove into the center of the remaining bolt in the engine head.
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Slowly increase speed up to full speed once you have a solid groove worked into the bolt. The bolt should begin to break up as you drill through it.
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5
Stop drilling periodically and use the magnetic wand to clear out any metallic filings and bolt pieces.
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Continue to drill until the bolt is removed from the cylinder head.
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